Before doing the final cut (or almost), the side baffles have to be cut down around the inlets. But first, the inlet ramps are clecoed to the upper cowl to get the correct shape. The ramps will be epoxied to the cowl later.



Here the baffles after the cut on both sides of the inlet. After a few installtions and removings of the cowl and baffles, I did the final cut and deburred all the parts.

Still working on the baffle cuts. The idea is to install the upper cowl and be sure that there is a 3/8 to 1/2" gap between the baffles and the cowl. As everything is hiddent once the cowl is closed, the following trick is used : first put some paper clips on the top of the baffles, then install the upper cowl and then measure te gap from the top of the clip.
As I'm cutting a few 1/16" each time, I needed a few iterations. I still have to make some adjustements.

I spent a good part of the afternoon, sanding, priming and riveting the forward and side baffles.
Some rivets where interesting to set, and I used a few pop rivets in places I feared I would damage the parts.
The picture shows the two finished parts.



With the parts bolted to the engine, came the time to cut of the height to be able to close the upper cowl.
The picture shows there will be quite a lot of material to cut off.
I progressed very slowly and still a couple 1/8" to cut off beafore tackling the final cut. This will be done next time.

The session begins with the bending of the tab of the vertical side that will later be riveted to the inlet ramp. No problems here except for the blurred picture.



Then I have to fabricate two small conical gussets for the exterior corners of the inlets; I begin by making a paper template.



And the result after almost one hour, the template was not very accurate and getting the shape is not very easy.



And the part for the other inlet, fabricated in a bit less time.



Then I installed the forward certical baffles and the small angles. The picture shows the problem I then discovered. There is a gap between the baffle and the cowl (in front of the small angle). To get the baffle in position I had to fabricate new angles on both sides.

Today I tackled the inlet ramps, the baffels are way to long and need to be bent to allow the lower cowl to be reinstalled.
All begin with the cutting along a guess line.



This is a view taken from the rear, the baffle is only tangent to the inlet towards the center, a bend will correct this.



The picture shows the diagonal bend (next picture is better) that lifts the outer corner of the ramp.
The vertical baffle also has to be shortened and bent to be tangent to the outer conner of the inlet.



This is the left side. A the idea was to progress slowly towards the final result so as to be on the safe side and not cut the parts too short, a lot of installations and removings where needed to get to this point.



This little bracket had to be fabricated for the left ramp.



After priming of the hidden parts, the ramps where riveted and reinstalled. Next job will be to drill and rivet the veritcal baffles to the ramps.